Terminal construction



1967 H. A. ELLIOTT 3,3353% TERMINAL CONSTRUCTION Filed July 19, 1965 United States Patent 7 3,335,392 v TERMINAL CONSTRUCTION Howard A. Elliott, Detroit, MICIL, assignor to Essex Wire Corporation, Fort Wayne, Ind., a corporation of Michigan Filed July 19, 1965, Ser. No. 473,111 6 Claims. (Cl. 339-97) This invention relates to terminal connectors particularly adapted for connection to wire wound-type ignition cables for automobiles.

One object of this invention is to provide an improved terminal connector formed of sheet metal or the like having a ferrule-forming portion and an electrical connector portion, the ferrule-forming portion including a base and prongs extending from said base for engaging with and retaining an ignition cable that comprises a central core of electrical conductive material enclosed by an insulating sheath, there being two spaced tabs extending from the base in parallel relationship to one another, the tabs being disposed between the prongs and being aligned transversely with respect to one another, the prongs being crimped onto the sheath of the ignition cable for causing the tabs to penetrate the sheath and firmly connect the ferrule-forming portion of the terminal connector to the ignition cable in electrical contact with the central core of electrical conductive material therein.

Another object of this invention is to provide an improved terminal connector for ignition cables that provides consistently reliable electrical connections. These and other objects of this invention will become more apparent hereinafter.

The specific details of the invention and their mode of functioning will be made most manifest and particularly pointed out in clear, concise and exact terms in conjunction with the accompanying drawings, wherein:

FIGURE 1 is a perspective view of a terminal connector embodying my invention and a length of wire wound resistance core ignition cable mechanically and electrically connected with the terminal connector;

FIGURE 2 is a side view of the terminal connector of FIGURE 1 prior to connection to the ignition cable;

FIGURE 3 is a top view of the terminal connector of FIGURE 1 prior to connection to an ignition cable;

FIGURE 4 is an end view of the terminal connector taken generally along the line 4-4 of FIGURE 3;

FIGURE 5 is a cross-sectional view taken generally along the line 55 of FIGURE 1 and illustrating the connection of the terminal connector to the ignition cable;

FIGURE 6 is a perspective view of another form of terminal connector embodying the principles of the present invention;

FIGURE 7 is a side view of the terminal connector of FIGURE 6 prior to connection to the ignition cable;

FIGURE 8 is a top view of the terminal connector of FIGURE 6 prior to connection to an ignition cable;

FIGURE 9 is a top view of the modified terminal connector taken generally along the line 9-9 of FIGURE 8;

FIGURE 10 is a cross-sectional view of the assembled terminal connector and ignition cable taken generally along the line 1010 of FIGURE 6, and

FIGURE 11 is a side view of another modified form of terminal connector.

Referring to the drawings, there is illustrated in FIG- URE 1 an ignition cable 10 having afiixed to the marginal end thereof a terminal connector 12 embodying the principles of the present invention. The ignition cable 10, which is adapted to be connected at one end to a spark plug and at the other end to the distributor in an automobile is comprised of a glass fiber core '14 over which is applied a resinous coating containing magnetic "ice ferrite particles. The resinous coating may be made from chloro-sulfonated polyethylene known commercially as Hypalon. A fine electrical conducting wire 16 is wound over the core. The wire 16, which is preferably made from Monel, may be coated with a layer of a semi-conductive material, such as semi-conductive neoprene. The core means is insulated by a pliable sheath comprising a rubber layer 18 and an outer jacket 20 of neoprene or chloro-sulfonated polyethylene.

The terminal connector 12 is comprised of an electrical connector portion 22 and a ferrule-forming portion 24. The electrical connector portion 22 is generally tubular and is defined by a pair of arm portions 23 that are adapted to be connected to a spark plug. Spherical portions 23 are stamped in each arm portion to facilitate engagement with a distributor terminal. The ferrule-forming portion is comprised of pairs of longitudinally spaced ears or prongs 26 and 28 for making both electrical and mechanical connection to the ignition cable 10. The prongs 28, which extend from the base of the ferrule-forming portion 24, are adapted to be crimped over and engaged with the sheath of the ignition cable for mechanically connecting the terminal connector to the ignition cable. The prongs 26 are similarly adapted to be crimped over to firmly engage the ignition cable 10.

Referring to FIGURES 2, 3, and 4, there is shown the terminal connector 12 prior to assembly to the ignition cable. The electrical connector portion 22 is formed to generally tubular shape so as to cooperatively engage with the terminal socket of a distributor.

Extending upwardly from the base 30 of the ferruleforming portion 24 of the terminal connector are a pair of prongs 28 that are adapted to provide the mechanical connection between the terminal connector and the ignition cable and a pair of prongs 26 that are adapted to cooperate with lugs 36 to electrically connect the terminal connector to the ignition cable 10. A ridge 32 may be provided extending transversely of base 30 in the arms or prongs 28 to enhance the mechanical connection of the arms 28 to the sheath of the ignition cable 10.

Two spaced insulation piercing lugs 36 are struck from the base 30 between the prongs 26. The lugs 36, which are generally triangular, as best seen in FIGURES 2 and 3, are in transverse alignment with one another between the prongs 26 and each of the lugs is disposed in parallel relationship to one another. If desired, the lugs may be of another configuration, as for example, rectangular or trapezoidal. The inner free end of lug 36 is relatively sharp and may be peaked to facilitate penetration of lag 36 through the sheath 20 about Wire 16 when connector 12 is crimped to cable 10. The lugs 36 are spaced apart less than the width of the core means within cable 10 and cooperate with prongs 26 to assure good electrical and mechanical contact of the connector 12 to the cable.

In FIGURE 5, there is best seen the connection of the terminal connector 12 to the ignition cable 10. It will be understood that the ignition cable 10 is disposed between the prongs 26 and 28 with the end of the ignition cable disposed closely adjacent to the shoulders 23 respectively, on the arm portions 23 that are adapted to engage the spark plug. The prongs 26 and 28 are then bent over or crimped over the sheath. The tabs 36 are constructed and arranged to penetrate the insulation 20 and 18 on the ignition cable 10 and to pass along opposite sides of the core means therewithin. The ignition cable 10 is forced upon the insulation piercing tabs 36 by the two prongs 26 during the crimping action. There is no necessity to force the tabs 36 into the insulation before crimping the terminla connector 12 to the end of the ignition cable 10.

The two prongs 26 have blunt edges and are not relied upon for making an electrical connection. Electrical contact is made between the tabs 36 and the electrically conductive material on the core means of the ignition cable.

It will be noted that a notch 40 is provided in the end of each prong 26. As shown, the notchm 40 may be triangular. The notches 40 insure that the prongs will not strike and displace the tabs 36 during crimping. The configuration of the notch can be varied, provided that there is a sufficient recess in the end of each prong 26 to assure that there is no contact with the tabs 36 during crimping of the prongs 26 onto the ignition cable.

Referring now to FIGURE 6, there is illustrated a modified form of terminal connector embodying the principles of the present invention. The terminal connector 112 is adapted to be connected to the end of a spark plug in an automobile. It will be understood that the terminal connector 12 may be aflixed at one end of the ignition cable and the terminal connector 112 may be afiixed to the other end of the ignition cable 10. Inasmuch as the ignition cable may be the same in both FIGURES 1 and 6, the same numerals are applied to common elements.

The terminal connector 112 comprises an electrical connector portion 122 and a ferrule-forming portion 124. The arm portions 123 of the electrical connector portion 122 are engaged with and affixed to a ring member or retainer 125 that is adapted to make connection to the spark plug.

The ferrule-receiving portion 124 includes prongs 128 having transversely disposed ridges extending along the length thereof. A plurality of lugs 129 are struck from the prongs 128 in order to provide better mechanical connection of the prongs 128 to the ignition cable when the arms or prongs 128 are crimped in placed. Provided on the terminal connector 112 area pair of prongs 126 that are adapted to cooperate with upstanding tabs on the ferrule-forming portion to electrically connect the terminal connector 112 to the ignition cable 10.

The terminal connector 112 is formed in a similar manner to the terminal connector 12. Prior to connection of the terminal connector 112 to an ignition cable, it is seen that the arms 126 extend upwardly and outwardly from the base portion 130 of the connector 112. Similarly, the prongs 128 extend outwardly from the base 130. The prongs 128 may be transversely ridged along the length thereof to provide for better engagement with the insulation on the ignition cable. In addition, a plurality of lugs 129 may be struck from the prongs 128 and the base 130 to further enhance a rigid mechanical connection between the ferrule-forming portion 124 and the ignition cable when the terminal connector 112 is crimped onto the end of the ignition cable.

Extending upwardly from the base 130 of the ferruleforming portion 124- of the terminal connector 112 are a pair of spaced and parallel disposed generally triangular lugs 136. The insulation-piercing lugs 136 are spaced apart a distance equal to or less than the diameter of the electrically conductive core means within the ignition cable 10. It is noted that the ends of the prongs 126 are notched or recessed as indicated at 40. The purpose of the notches 140 in the prongs 126 is to provide clearance between the tops of lugs 136 and the ends of prongs 126 when the prongs 126 are crimped to the ignition cable 10. The ends of the prongs are blunt and are not relied upon for making the electrical connection.

In FIGURE 10, there is illustrated a cross-sectional view of the connection between a terminal connector 112 and the ignition cable 10. It will be seen that when assembled the electrically conductive wire 16 of the ignition cable 10 is disposed between the upstanding lugs 136 in engagement therewith, and the ends of the prongs 126 bear down upon the ignition cable to assure a good electrical connection between the lugs 136 and the wire 16 on the core means within the cable 10.

In FIGURE 11, there is illustrated another form of terminal connector 212 wherein the electrical connector portion 222 extends at an angle from the ferrule-forming portion 224. It will be apparent to those having skill in the art that the electrical connector portion 222 may extend at an angle of approximately to the ferruleforming portion 224, as illustrated in FIGURE 11, or at another angle depending upon the use to which the ignition cable may be put.

There has been provided by the present invention an improved solderless terminal connector for engaging with the end of an ignition cable so as to provide consistently reliable electrical connections. Provided on the terminal connector are pairs of spaced prong means. A first pair of prong means cooperate to mechanically interconnect the terminal connector and the ignition cable. The second pair of prong means cooperate with upstanding lugs formed on the base of the ferrule-forming portion of the terminal connector to enhance the mechanical interconnection and to provide an intimate electrical contact with the electrically conductive core means of the ignition cable. By virtue of the present invention, there is no necessity for stripping the insulation from the ignition cable in order to provide for firm mechanical and electrical connection of the terminal connector to the ignition cable.

While I have described and illustrated preferred embodiments of my invention, it will be understood my invention is not limited thereto since it may be otherwise embodied within the scope of the following claims:

I claim:

1. A crimp-on type terminal connector for an ignition cable having an electrically conductive core enveloped by an insulated cover, said terminal connector comprising a body member having a ferrule-forming portion for engaging the ignition cable and an electrical connector portion, said ferrule-forming portion including a base and a pair of prongs extending from said base for engaging with and retaining said ignition cable, said base having a pair of spaced lugs extending therefrom between said prongs and being transversely aligned with respect to the longitudinal axis of the cable and to said prongs, said prongs having blunt ends and said blunt ends being recessed so that when the prongs are crimped to the ignition cable, the lugs will penetrate the insulated cover and engage with the electrically conductive core without interference between the blunt ends of the prongs and the lugs, the electrically conductive core being retained between the blunt ends of the prongs and the lugs, thereby insuring a firm and reliable mechanical and electrical connections between the terminal connector and the electrically conductive core.

2. A crimp-on type terminal connector as in claim 1 wherein a second pair of prongs extend from the base of the ferrule-forming portion and are crimped to the ignition cable for strengthening the mechanical connection of the terminal connector to the ignition cable.

3. A crimp-on type terminal connector as in claim 1 wherein said spaced lugs each have a relatively sharp peak at the inner free end thereof for facilitating penetration of said insulated cover.

4. In an improved connection between an ignition cable having a central core means comprising electrically conductive material and a surrounding sheath of pliable insulating material, and a terminal connector comprising a sheet metal member having a ferrule-forming portion and an electrical connector portion, said ferruleforming portion including a base and prongs extending from said base for engaging with and retaining said ignition cable, the improvement comprising said base having two side by side spaced tabs extending therefrom in parallel relationship to one another, said tabs being disposed between said prongs and being transversely aligned with respect to the longitudinal axis of the cable and to said prongs, said tabs being formed so as to readily penetrate said surrounding sheath, said prongs having the ends thereof notched transversely of said tabs, said prongs being bent over about said sheath and the ends thereof engaging said sheath on opposite sides of said core means to force said tabs into said sheath and into engagement with said electrically conductive material, said notched end portions of said prongs insuring that there is no interference with the tabs when the ferrule forming portion is joined to the ignition cable, the prongs and tabs cooperating also to provide secure mechanical connection between the ignition cable and the terminal connector.

5. An electrical connection between a Wire-wound core electric cable including an insulating sheath surrounding the core and a terminal connector comprising a sheet metal member having a ferrule-forming portion and an electrical connector portion, said ferrule-forming portion having a base and first prongs and second prongs defining a tube opening at one end and being adapted to receive the marginal end of said electric cable, a pair of side-by-side spaced piercing lugs extending from said base between said first prongs, said piercing lugs being aligned transversely with respect to the longitudinal axis of the cable and being adapted to penetrate said insulating sheath on said electric cable to engage with and make electrical connection With said wire-Wound core, said first prongs being crimped to said electric cable to force the piercing lugs to penetrate said insulating 6 sheath and engage the wire-wound core so as to make electrical contact therewith, and restrain the Wire-wound core from sidewise movement, said second prongs being crimped to the marginal end of said electric cable to make a firm mechanical connection between said terminal connector and said electric cable.

6. An electrical connection as in claim 5 wherein said piercing lugs are generally triangular and have a relatively sharp and peaked inner free end to facilitate penetration of the insulating sheath.

References Cited UNITED STATES PATENTS 2,651,025 9/1953 Elliott 33997 3,077,027 2/1963 Sola et al 33997 3,223,963 12/1965 Rarey et al 339259 3,259,874 7/1966 Esser 33997 FOREIGN PATENTS 88,740 2/ 1958 Netherlands.

MARVIN A. CHAMPION, Primary Examiner. EDWARD C. ALLEN, Examiner. J. H. MCGLYNN, Assistant Examiner. 

1. A CRIMP-ON TYPE TERMINAL CONNECTOR FOR AN IGNITION CABLE HAVING AN ELECTRICALLY CONDUCTIVE CORE ENVELOPED BY AN INSULATED COVER, SAID TERMINAL CONNECTOR COMPRISING A BODY MEMBER HAVING A FERRULE-FORMING PORTION FOR ENGAGING THE IGNITION CABLE AND AN ELECTRICAL CONNECTOR PORTION, SAID FERRULE-FORMING PORTION INCLUDING A BASE AND A PAIR OF PRONGS EXTENDING FROM SAID BASE FOR ENGAGING WITH AND RETAINING SAID IGNITION CABLE, SAID BASE HAVING A PAIR OF SPACED LUGS EXTENDING THEREFROM BETWEEN SAID PRONGS AND BEING TRANSVERSELY ALIGNED WITH RESPECT TO THE LONGITUDINAL AXIS OF THE CABLE AND TO SAID PRONGS, SAID PRONGS HAVING BLUNT ENDS AND SAID BLUNT ENDS BEING RECESSED SO THAT WHEN THE PRONGS ARE CRIMPED TO THE IGNITION CABLE, THE LUGS WILL PENETRATE THE INSULATED COVER AND ENGAGE WITH THE ELECTRICALLY CONDUCTIVE CORE WITHOUT INTERFERENCE BETWEEN THE BLUNT ENDS OF THE PRONGS AND THE LUGS, THE ELECTRICALLY CONDUCTIVE CORE BEING RETAINED BETWEEN THE BLUNT ENDS OF THE PRONGS AND THE LUGS, THEREBY INSURING A FIRM AND RELIABLE MECHANICAL AND ELECTRICAL CONNECTIONS BETWEEN THE TERMINAL CONNECTOR AND THE ELECTRICALLY CONDUCTIVE CORE. 